MAN B&W Diesel A/S
Alpha Lubricator
Alpha System
Lubricator System
Alpha Lubricator System
PCS/2440/2001.10.23
Alpha Lubricator System
Reason for development of our new Alpha Lubrication system.
• Reduction of the Lube oil consumption
• Reduction of the Emission level
• Element for our Intelligent Engine Concept
Alpha Lubricator System
PCS/2440/2001.10.23
Spec. consump. g/Bhph at MCR
0
0,2
0,4
0,6
0,8
1
1,2
1,4
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84VT2BF180 8.5 bar
0,26
42VT2BF90 8.5 bar
0,39
K84EF 9.5 bar
0,24
K98FF 10 bar
0,21
L90GF 11.6 bar 0,35
K/L45GF 12 bar
0,45
Alpha Lubricator System
K/L90GFCA 12.9 bar
Engine type
0,35
K/L45GFCA 13 bar
0,45
K/L-GB 15 bar
0,5
K/L/S-MC MK I-III 17 bar
0,6
1
K/L-MC MK V-VI 18 bar
S-MC MK V-VI 18 bar
1,2
Cylinder oil feed rate in the period 1965 to 2000
Alpha Lubricator System
Possible Saving with a 12K90MC
Operating at
85% power corresponding to 65.000 BHP
and operating 7.000 hour/year
with
0,1 g/bhph reduction of cylinder lub oil consumption
result in a saving of
Alpha Lubricator System
45,5 tons lub oil per year corresponding to
a US $ 60.000,- saving per year
PCS/2440/2001.10.23
Alpha Lubricator System
Lubrication principle
• The lubrication principle is intermittent lubrication where an engine
cycle with lube oil injection is followed by one or more (normally 4
cycles without oil injection.
• The injection is timed in relation to the position of the piston ring.
• The specific feed rate is controlled by variation of the injection
frequency.
Alpha Lubricator System
• Adjusting of the feed rate in relation to MEP and LCD lubrication
is standard.
• Pre-lubrication of the cylinder can be done just before start of the
engine.
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Function of Injection Pattern
Alpha Lubricator System
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System Layout
Alpha Lubricator System
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System Diagram
Alpha Lubricator System
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System Diagram
Alpha Lubricator System
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Master Control Unit, MCU
Alpha Lubricator System
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Alpha Lubricator Control Unit
Alpha Lubricator System
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Alpha Lubricator Control Unit
Alpha Lubricator System
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Electronic Control Units
Master Control Unit, MCU
• Exact timing of lube oil injection, calculation of oil-rate.
• Handles: LCD, Prelubrication, individual cylinder lubrication setup etc.
• Pump station control.
Backup Control Unit, BCU
• Supervision of MCU and lubricators.
• Automatic takeover of lubricator control through SBU in failure situation.
• Simple pseudo random lubrication algorithm.
Switch Board Unit, SBU
Alpha Lubricator System
• Switches the control of the lubricators from MCU to BCU.
• Switching is controlled either by BCU or by manual switch.
Display Unit, OB module
• Display of different operating conditions: RPM, Fuel Index, alarms.
• Setup of individual cylinder lubrication.
PCS/2440/2001.10.23
Lubricator
Alpha Lubricator System
Solenoid valve
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Lubricator
Alpha Lubricator System
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Lubricator
Solenoid valve - deactivated Signal for lubrication
Capacitive feed-back sensor from control unit
for control of piston
movement
Outlets for
cylinder liner Injection
lube oil plungers
Solenoid
valve
Alpha Lubricator System
Cylinder lube
Adjusting Actuator oil inlet
Spacer for basic setting of
screw piston
pump stroke
Cylinder lube
oil outlet
PCS/2440/2001.10.23
Lubricator
Solenoid valve - deactivated
Alpha Lubricator System
PCS/2440/2001.10.23
Lubricator
Solenoid valve - activated
Alpha Lubricator System
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Injection Nozzle
Alpha Lubricator System
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Modified Pump Station
Alpha Lubricator System
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Pump Station Without Cooler (Diagram)
Alpha Lubricator System
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Installation in Engine Room
Alpha Lubricator System
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Basic data
Cylinder lub. oil Number of Lub oil Injection frequency. Pump
consumption Lubricator per quills per Revolutions Pump Piston Stroke Station
g/bhph Cylinder cylinder between injections mm mm m 3/h
S26MC 1,1 1 3 6 3,5 10,00 0,4 - 0,8
L35MC 0,9 1 4 6 3,5 10,00 0,4 - 0,8
S35MC 1,1 1 4 5 3,5 10,25 0,4 - 0,8
L42MC 0,9 1 4 6 4,5 10,25 0,4 - 0,8
S42MC 1,1 1 4 4 4,5 10,75 0,4 - 0,8
S46MC-C 1,1 1 6 4 4,5 11,00 0,4 - 0,8
L50MC 0,9 1 6 6 4,5 11,25 0,4 - 0,8
S50MC-C 1,1 1 6 4 4,5 11,25 0,4 - 0,8
S50MC-C 1,1 1 6 4 4,5 11,50 0,4 - 0,8
L60MC 0,9 1 6 6 6 11,75 0,4 - 0,8
S60MC 1,1 1 6 4 6 12,00 0,4 - 0,8
S60MC-C 1,1 1 6 4 6 12,00 0,4 - 0,8
L70MC 0,9 2 8 6 7 12,25 0,4 - 0,8
Alpha Lubricator System
S70MC 1,1 2 8 4 7 12,50 0,4 - 0,8
S70MC-C 1,1 2 8 4 7 12,75 0,4 - 0,8
K80MC-C 0,9 2 8 4 7 12,75 0,4 - 0,8
L80MC 0,9 2 8 4 7 13,00 0,4 - 0,8
S80MC 1,1 2 8 3 7 13,00 0,8 - 1,2
S80MC-C 1,1 2 8 3 7 13,50 0,8 - 1,2
K90MC-C 0,9 2 10 4 7 13,75 0,4 - 0,8
K90MC 0,9 2 10 4 7 13,75 0,4 - 0,8
L90MC-C 0,9 2 10 3 7 13,75 0,4 - 0,8
S90MC-C 1,1 2 10 3 7 14,25 0,8 - 1,2
K98MC-C 0,9 2 10 4 7 14,25 0,8 - 1,2
K98MC 0,9 2 10 4 7 15,25 0,8 - 1,2
PCS/2440/2001.10.23
Service Test
Test on 10K90MC-C Mk 6 by retrofitted it with Alpha lubricator in April 2000 at
16,500 running hours.
Condition of pistons and piston rings at 22,082 running hours with 0.57 g/bhph.
Alpha Lubricator System
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Service Test
Ongoing service test on 6S90MC-C with Alpha
Lubricator System.
Inspection after 2000 hours – excellent condition.
Alpha Lubricator System
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Guiding Oil Feed Rates
Revised guiding cylinder oil feed rates:
L and K-MC/MC-C engines Guiding cylinder oil feed rate
Mechanical lubricators 0,6-0,9 g/bhph
Alpha Lubricator System 0,5-0,8 g/bhph
Oil feed rate for S-type engines are waiting results of service test.
Alpha Lubricator System
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Alpha Lubricator on 12K98MC-C
Alpha Lubricator System
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Alpha Lubricator on S50MC-C
Alpha Lubricator System
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